Immersion heater mounting



July 6, 1965 E. L. BRANDT 3,193,652

IMMERSION HEATER MOUNTING Filed Aug. 9, 1961 2 Sheets-Sheet l I l y IMLI. a I l Wwf July 6, 1965 E. BRANDT 3,193,662

IMMERSION HEATER MOUNTING Filed Aug. 9, 1961 2. Sheets-She'at 2 *Ilm-lullin IN VEN TOR.

United States Patent O 3,193,662 IMMERSIGN HEATER MQUNTING Erwin L. Brandt, Olivet, Mich., assigner to McGraw-Edison Company, Milwaukee, Wis., a corporation of Delaware Filed Aug. 9, 1961, Ser. No. 130,414 10 Claims. (Cl. 21g-336) This invention relates to immersion heaters and, more particularly, to a new and improved mounting for affixing an immersion heater to a mounting surface such as the tank wall of a water heater.

An object of this invention is the provision of a simplified and effective mounting for an immersion heater at lower cost.

Another object of this invention is the provision of a mounting assembly for an immersion heater including single clamping means for tightening the mounting assembly on a mounting surface.

Another object of this invention is the provision of a mounting for an immersion heater which, without the need for welded fittings, securely clamps to the mounting surface and produces a tight seal.k

A further object of this invention is the provision of a mounting for an immersion heater which cooperates with the mounting surface to prevent rotation of the heater relative to thek mounting surface during mount- A still further object of this invention is the provision of -a mounting for an immersion heater which also includes a simplified mounting for a thermostat or temperature limit controls.

The novel features of my invention are set forth in the appended claims. The invention itself, together with additional objects and advantages thereof, will be more clearly understood from a reading -of the following description in connection with the accompanying drawings wherein: FIG. 1 is a front elevation of a preferred embodiment of my invention;

rFIG.y 2 is a cross sectional view taken along lines 2-2 of FIG. l;

FlG. 3 is a cross sectional view taken along lines 3-3 of FIG. 2;

FIG. 4 is a side elevation, partially in cross section, of the heating element assembly and the inner flange of the mounting assembly;

PIG. 5 is a side elevation of the mounting assembly;

FIG, 6 is a front elevation of an alternate embodiment of my invention;

FIG. 7 is a cross sectional view taken along lines 7-7 of FIG. 6; and

PIG. 8 is a cross sectional view taken along lines 8 8 of FIG. 7.

A heater assembly 1 is illustrated as connected to a mounting surface such as a tank wall 2 of a hot water heater. The heater assembly 1 is disposed at an aperture 3 in the tank wall so that an electric resistance heating yelement 4 can extend into the tank. The heating element 4 has a closed end 5 disposed within the` tank and arms 6 and 7 which extend through the aperture 3 and terminate exteriorly of the tank. The heating element 4 generally comprises an internal, coiled electric resistance wire 8 with an exterior metallic sheath 9 and a refractory material 10a, such as magnesium oxide, lilling the interior of the sheath and insulating the electric coil from the sheath. i

The exterior ends of the arms 6 and 7 are provided with electrical terminal connections 10 and 11 respectively, to which electrical leads can be attached to supply electrical power to the heating element. The resistance coil 8 extends through the exterior ends of arms 6 and 7 and electrically connect to the terminals 10 and 3,193,662 latented July 6, 1965 ICC 11 to complete a circuit for the passage of electric current through the heating element 4 to raise the temperature of the water (not shown) within the tank.

Disposed between each of the exterior ends of the arms 6 and 7 and their respective electrical terminals 10 and 11 is a spacer k12 of suitable electrical insulating material to electrically insulate the metallic sheath of the heating element from the terminals 10 and 11.

A mounting assembly 13 is provided for securely connecting the heating element 4 to the tank wall 2. The mounting assembly 13 includes an inner flange 14 having an integrally formed stud 15 which extends through the aperture 3. A gasket 16 is provided with an aperture 17 and tits onto the stud 15. The gasket 16 includes a peripherally extending portion 18 which is disposed between the inner flange 14 and the tank wall 2, and a raised portion 19 which is shaped to conform to and is disposed in the aperture 3. An outer flange 20 is provided with an aperture 21 to lit on the stud 15 and is disposed exteriorly of the tank Wall 2. The outer end 22 of the stud 15 is threaded to receive a nut 23. When the nut 23 is threaded onto the stud 15 it engages the outer flange 2t) so that tightening of the nut 23 urges the outer flange Ztl and the inner flange 14 together to securely clamp the tank wall 2 therebetween. The clamping action of the outer and inner flanges also clamps the peripheral portion 1li of the gasket between the inner tlange and the tank wall to establish a watertight seal at the aperture 3.

The arms 6 and 7 of the heating element 4 extend through suitable apertures 24 in the inner tinage, 25 in the gasket 16, and 26 in the outer flange. With this arrangement the heating element 4 is in engagement with and maintains the inner ange, gasket and outer ilange in proper relative alignment. A small amount of solder 27 is applied at the juncture of the -arms 6 and 7 and the inner ange 14 to provide a rigid and waterproof connection therebetween.

Thus it can be seen that a secure and watertight connection of the heating element 4 to the tank wall 2 is accomplished through the simple expedient of tightening a single nut.

Referring to FIG. 3, the aperture 3 is generally elliptical in shape and the raised portion 19 of the gasket 16 is also generally elliptical to conform to and t snugly within the aperture 3. The elliptical configuration of the aperture 3 is preferred; however, other non-circular shapes can be used with the raised portion 19 of the gasket having a conforming shape. The non-circular configuration of the aperture 3 and the raised portion 19 cooperate to prevent rotation of the heater assembly 1 during clamping, i.e. with the raised portion 19 being disposed within and conforming to the non-circular configuration of the aperture 3, and since the elements of the mounting vassembly 13 are all held in relative alignment by the heating element 4, the heating unit 1 cannot rotate as the vnut 23 is tightened to clamp the mounting assembly to the tank wall. Apertures 28 are provided in the outer flange 2l) and serve as sight holes so that a visual check yof the gasket 16 can be made to insure proper alignment of the raised portion 19 and the apertures 3 prior to tightening of the nut 23.

Included in the heater assembly 1 is an electrical resistor 29. One end 3l) of the electrical resistor is clamped in electrical engagement with the tank wall by the peripherally extending edge 31 of the outer flange 20. The other end 32 of the resistor is electrically connected to the mounting assembly as by soldering or welding it to the outer flange 20. In a manner well known in the art this resistor operates to reduce electrolytic corrosion problems. Furthermore, an electrical insulator 33 is disposed between the louter flange 2li andthe tank wall areas-lea 2 to electrically insulate the outer flange from the tank wall. The gasket f6 serves to electrically insulate the inner flange 14 from the tank wall. Therefore, the mounting assembly lll is electrically insulated from the tank wall except for the electrical connection through the resistor 29.

Extending laterally from the outer flange 2f) are a pair of relatively spaced, generally parallel arms 34. As can be seen in FG, 5, these arms are spaced from the tank wall 2. lrisposed between the arms is a thermostatic control 35, the details of the control are well known in the art and hence are neither illustrated nor described. The thermostatic control 35 is suitably mounted in a metal carriage 36 which includes raised, laterally extending ears 37. The ears 37 engage the arms 34 and the arms 34 have specially formed end portions 3S for holding the thermostatic control against longitudinal movement relative to the arm 34. As the nut 23 is tightened to the clamp the tank wall 2 between the inner and outer flanges the arms 34 also clamp the thermostatic control 35 in secure, intimate engagement `with the tank wall so that it can accurately sense the temperature of the water and control the energization of the heating element 4 accordingly.

FIGS. 6 8 illustrate an alternate embodiment of my invention. Here too a heating element 39 extends through an aperture 4u in a tank wall 2. The exterior ends of the heating element are provided with electrical terminals 41 for electrically connecting the heating element t-o a source of electrical energy.

The heating element 39 is fixedly clamped to the tank wall 2 by a mounting assembly 42. The mounting assembly 42 includes an inner flange 43 having a stud 44 rigidly connected thereto and extending through the aperture 4f). Disposed on the stud 44 exteriorly of the tank wall 2 is an outer flange 45 and a sleeve 46. The stud 44 is threaded and extends through the sleeve 45 and receives a nut 47. Disposed between the tank wall 2' and the inner flange 43 is a gasket 48.

The heating element 39, as in the preferred embodiment yof FIGS. 1-5, passes through suitable apertures in the inner flange 43 and outer flange 45 to maintain relative alignment between these elements. As the nut 47 is threaded onto the stud 44 the sleeve 46 abuts the outer flange 45 and tightening of the nut urges the outer and inner flanges together and securely clamps the tank wall `2. therebetween. Also the gasket 4S is securely clamped between the inner flange 43 and the tank wall to provide a watertight connection at the aperture 4l?. As can be seen in FIG. 7, the gasket 48 extends around the juncture between the inner flange 43 and the aperture 4l) to insure a watertight seal. Again the connection of the mounting assembly and the achievement of a watertight seal is accomplished by merely tightening one nut.

Referring now to FIG. 8, the aperture 40 is generally elliptical in shape. The inner flange 43 has a raised central portion 49 that cooperates with the axially extending portion of gasket 48 to form a composite projecting portion which is also elliptical in shape to conform to the shape of the aperture 4u. Gasket 48 is secured to the flange 43 by engagement with the radially facing surface of flange raised porti-on 49 so that flange 43, gasket 48 and heating element 3h are retained together as a single positively aligned unit during positioning and assembly. During the tightening operation the lraised portion 49 is disposed within the aperture 4f) and prevents rotation of the heating element 39 and the mounting assembly 42.

In the embodiment of FIGS. 6-8 the outer flange 45 is electrically insulated from the tank wall Z by an insulating member Sil and the inner flange 43 is electrically insulated from the tank wall by the gasket 4S. An electrical resistor Slt is connected between the outer flange and the tank wall to reduce electrolytic corrosion.

The discussion and explanation of my invention with reference to particular embodiments thereof is intended for illustrative purposes only and not by way of limitation, for it is recognized that those skilled in the art, with the benefit of this disclosure, will perceive additional embodiments of my invention. Accordingly, it is intended in the appended claims to cover all modifications and embodiments of my invention as fall within the true spirit and scope thereof.

What I claim is:

ll. In combination with a tank wall provided with a generally elliptical aperture having a continuous boundary wall, an electrical resistance heater disposed at and extending through said aperture; a first flange disposed at the inner side of said tank wall connected to and suppoiting said heater, said first flange including `a threaded stud member rigidly fixed thereto and extending through said aperture and exteriorly of said tank wall; a gasket engaging said heater and disposed in surrounding relation to said heater and stud between said first flange and said tank wall, said gasket including a raised central portion disposed in said aperture and engaging said boundary wall at least at one point lying on either side of the axis of said elliptical aperture so as to position said gasket relative to said wall and resist rotation therebetween; a second flange member engaging said heater and disposed on the outer side of said tank wall; and means threadedly engaging said stud for movement thereon to engage said second flange for urging said first and second flanges toward engagement to clamp said tank wall and said gasket therebetween.

2. The combination in claim l wherein said second flange is provided with at least one aperture disposed in alignment with said raised portion of said gasket.

3. In combination with a mounting wall provided with a generally elliptical aperture having a continuous bound- `ary wall and an electrical resistance heater, an assembly for mounting .said heater through said aperture comprising a first flange connected to and supporting said heater and disposed at s-aid Yaperture on the one side of said mounting wall and including an elongated portion extending through said aperture; a gasket disposed between said first flange and said one side of said mounting wall and including .a portion disposed within and having a :conguration conforming in size and shape to that of said generally elliptical aperture to position said gasket rela- .tive to said wal-l; restraining means precluding rotation of said gasket relative to said first flange; a second flange member disposed at said aperture adjacent the side of said mounting wall opposite said one side; and means disposed on said elongated portion of said first flange for movement relative thereto to urge said first and second flanges toward engagement and clamp said mounting Wall Iand Ysaid gasket therebetween.

y4. In combination with a mounting wall provided with a non-circular aperture having a continuous boundary wall and an electrical resistance heater, a mounting assembly comprising a first flange member connected to and supporting said heater and disposed at said aperture on one side of said mounting wall; a second flange member disposed at said aperture on the side of said mounting wall opposite said one side; a gasket member disposed between said first -and second flange members engaging said mounting Wall in surrounding relation to said .aperture and including a 4raised portion disposed in and conforming in size `and shape to said non-circular aperture whereby during assembly of said mounting assembly to said mounting wal-l said gasket member raised portion serves to position said mounting assembly with respect to said mounting wall; retraining means for precluding rotation of at least said gasket member and .said first flange member relative to one another; and single clamping means interconnecting said first and second flange members for urging said flange members toward engagement to Iclamp said mounting surface and said gasket therebetween.

5. I-n combination with a container wall provided with a non-circular aperture having a continuous boundary wall and an electrical resistanceheating element, a mounting assembly for said heating element comprising a first flange member adjacent the interior surface of said container wall presenting a marginal portion in surrounding relation to said aperture, said heating element extending through said first flange member and carried thereby as a unitary structure; a gasket member overlying said first flange member intermediate said first flange member and said interior surface with a marginal portion in surrounding relation to said aperture and positioned with respect to said first flange member by engagement with the surface of said heating element; a second flange member adjacent t'he exterior surface of said container wall having a marginal portion at least parti-ally surrounding said aperture; .a raised port-ion presented by one of said first flange member and said gasket member disposed in said aperture an-d engaging at least two opposed points on said boundary wall of said non-circular aperture to prevent rotation of said firs-t flange member with respect to said aperture; and clamping means act-ing along the axis of said assembly to draw said flange members toward engagement to clamp said wall and said gasket therebetween.

6. In combination with a tank wall provided with a non-circular `aperture having a continuous boundary wall and an electrical 4resistance heater, a mounting assembly comprising a first flange connected to and supporting said heater and disposed at said aperture adjacent one side of said `tank wall; a gasket intermediate said first flange and said wall having a first portion margining said aperture and a second portion extending into said aperture and engaging at least two opposed points on said boundary wall of said non-circular aperture to prevent rotation of said gasket with respect to said tank wall; means preventing yrotation of said gasket with respect to said first flange; a second flange disposed adjacent said aperture adjacent the opposite of said one side of said tank wall; and clamping means interconnecting said first and second flanges and operative to draw said flanges toward engagement to clamp said wall and said gasket therebetween.

7. The mount-ing assembly of claim 6 wherein said means Preventing rotation of said gasket with respect to said first flange comprises an axially extend-ing non-round projecting portion presented by said first flange with said gasket second portion in surrounding engagement with the yaxially extending surface thereof.

`8. In combination with an electrical resistance heater and a ,Wall having a non-circular aperture therethrough, a mounting assembly comprising a first flange connected to and supporting said :heater and disposed at said aperture at one side of said wall; a gasket disposed adjacent said .aperture with a first portion margining said aperture between said first flange and said one side of said wall and a second portion :disposed within said aperture and having aconfiguration conforming in size and shape to said aperture to position said gasket relative to said wall; means preventing rotation of said gasket with relation to said first flange member; a second flange member disposed at said aperture adjacent the side of said wall opposite said one side; and clamping means interconnecting said first and second flange members for drawing said flanges toward engagement to clamp said wall and said gasket therebetween.

9. In combination with an electrical resistance heater and la tank wall provided with generally elliptical aperture having a continuous boundary wall, a mounting assembly comprising an elliptical rst flange connected to and supporting said heater and [disposed .adjacent the interior tank wall surface in surrounding relation to said aperture, said first flange including an elongated portion extending Ithrough said aperture; a second flange disposed at said aperture on the opposite side of said tank wall; a gasket disposed between said first flange andv said tank wall and engaging said tank wall in surrounding relation to sai-d aperture; means for restraining said gasket against rotation relative to said first flange, said gasket presenting a raised portion of substantially simil-ar configuration to said Iaperture and extending into said aperture andcontacting said boundary wal-l to position said first flange with respect to said tank wall; and means disposed on said elongated portion and movable relative thereto to engage said second flange for urging said flanges toward engagement to clamp said tank wall and said gasket therebetween.

10. In combination with a tank wall having -a generally elliptical aperture therein, an electric heater mounting assembly comprising a generally elliptical first flange member disposed at the inner side of said tank wall with a peripheral marginal portion overlapping said tank wall; a sheathed electric resistance heating element connected to and supported by said fir-st flange with end portions thereof extending through said first flange and said aperture; a gasket having a marginal portion disposed between said first flange and said tank wall and a central raised portion extending into said aperture and conforming thereto sufficiently to prevent rotation of said gasket with respect to said tank wall, said gasket surroundingly engaging said heating element end portions whereby relative rotation between said gasket and said first flange is prevented; a second flange member disposed at sai-d aperture adjacent the youter side of said tank wall and clamping means interconnecting said first and second flange members for yurging said flanges toward engagement to clamp said wall an-d said gasket therebetween.

References Cited by the Examiner UNITED STATES PATENTS 2,030,460 2/36 Morton 219-541 X 2,550,751 5/51 Adams 2119-536 2,575,150 1l/5 1 Wellman 2119-328 2,7445 5 9 5 5 6 Leonetti a- 285-208 2,757,271r 7/ 5 6 Fitzgerald 219-5 36 2,835,305 5/58 Boyer 285-206 FOREIGN PATENTS 390,715 4/ 33 Great Britain.

860,7 32 2/ 61 Great Britain.

13 8,804 6/ 3 0 Switzerland.

190,184 6/57 Austria. 1,059,165 11/53 France.

RICHARD M, WOOD, Primary Examiner.

MAX L. LEVY, ANTHONY BARTIS, Examiners. 

6. IN COMBINATION WITH A TANK WALL PROVIDED WITH A NON-CIRCULAR APERTURE HAVING A CONTINUOUS BOUNDARY WALL AND AN ELECTRICAL RESISTANCE HEATER, A MOUNTING ASSEMBLY COMPRISING A FIRST FLANGE CONNECTED TO AND SUPPORTING SAID HEATER AND DISPOSED AT SAID APERTURE ADJACENT ONE SIDE OF SAID TANK WALL; A GASKET INTERMEDIATE SAID FIRST FLANGE AND SAID WALL HWAVING AFIRST PORTION MARGINING SAID APERTURE AND A SECOND PORTION EXTENDING INTO SAID APERTURE AND ENGAGING AT LEAST TWO OPPOSED POINTS ON SAID BOUNDARY WALL OF SAID NON-CIRCULAR APERTURE TO PREVENT ROTATION OF SAID GASKET WITH RESPECT TO SAID TANK WALL; MEANS PREVENTING ROTATION OF SAID GASKET WITH RESPECT TO SAID FIRST FLANGE; A SECOND FLANGE DISPOSED ADJACENT SAID APERTURE ADJACENT THE OPPOSITE OF SAID ONE SIDE OF SAID TANK WALL; AND CLAMPING MEANS INTERCONNECTING SAID FIRST AND SECOND FLANGES AND OPERATIVE TO DRAW SAID FLANGES TOWARD ENGAGEMENT TO CLAMP SAID WALL AND SAID GASKET THEREBETWEEN. 